Thank you. All suggestions welcome, as I am making this up as I go along.
I designed these rib shapes in illustrator and they are not really perfect. Also scale is not really as accurate as it should be in illustrator. For whatever reason I had to print the template out at 110% to fit the cardboard pieces I scanned in originally. I'f I started spending money on this project I'd really like to make sure I knew it would be worthwhile.
To do this right It needs to be modeled in 3D. After seeing how my extrapolated 2D shapes fit to the car I'm actually considering changing a few things. I'm not well versed in 3dsmax or inventor. Wish I was, and keep saying I'm going to work on that. The only 3d Program I am decent with is strata studio. I don't have a copy any more and furthermore I haven't used it in probably 11 years. I have enough trouble remembering how to use In design and photo shop when I need it.
If I was able to design all the the pieces to fit together (without cutting foam) in one of those programs I would definitely have them made. With a couple alignment dowels so everything stacked perfectly? That would be sweet, but as soon as I have to sand something to shape pieces myself, this is where the variation comes in. I'm pretty sure in this particular case without a complete redesign I wouldn't be much better off with jetted templates over my wooden ones. Mostly because of the crudeness of the original 2D drawings and the methods I'm using to cut and shape foam (jig saw, kitchen knife, Bench grinder). This is being made in a movie prop / art project manor and not so much engendering. I don't have the experience or resources to do the latter.
It's raining out here today I don't know if that adversely effects the way body filler cures or not. I'm going to put this off just in case.
I need to start insulating my house and changing windows before it gets colder. I'm running out of days before my next side work project takes up all my spare time. I was suppose to start it this Tuesday. Everything has been held up and is out of my control.